Apparatus and system for installing rivets in belt fasteners

ABSTRACT

A system for splicing a conveyor belt with belt fasteners is disclosed. A base assembly aligns the belt, belt fasteners and rivet holes thereof with swage structures for securing the rivets. A guide assembly has a rigid guide block with cylindrical pilot holes, and a guide membrane of resilient material. Guide pins are receivable by guide bores for aligning the base and guide assemblies with the pilot holes, rivet holes, and swage structures in registry. The guide membrane including openings aligned with the pilot holes. The openings have a pair of slits defining flaps deflectable to permit the rivet to pass therethrough, and a central hole or cut-out. The flaps and the cut-out assist in centering the rivet with the belt fastener rivet holes. The system uses a single-rivet driver, a multi-rivet driver, a pneumatic driver, or an electric hammer.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of prior application Ser. No.11/397,207, filed Apr. 4, 2006, titled “Apparatus and System forInstalling Rivets in Belt Fasteners,” the entirety of which isincorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to installing rivets in belt fasteners and, inparticular, to a system and tools for installing rivets in beltfasteners for conveyor belts.

BACKGROUND

Currently, there are a number of systems known and utilized forinstalling rivets in belt fasteners for coupling portions of a conveyorbelt. In a simple form, a conveyor belt is a loop formed by a strip ofconveyor belt material having two ends that are connected or coupledtogether. The connection or coupling is referred to as a belt splice,particularly when the connection is used to repair a broken portion ofthe belt. The belt material is often formed from a relatively hard,though flexible, rubber material and a number of layers typicallyincluding at least one webbing layer. The rubber provides flexibilityand rigidity while the webbing layer minimizes or controls stretching,for instance. In this manner, the belt material is formed so as tomaintain a general length and shape, particularly when installed on apulley system and stressed during service.

The service demands of the conveyor belt require a relatively strong,yet flexible, connection or splice between the belt ends. Accordingly,the ends are commonly coupled, hinge-like, by opposed belt fastenerswhich are then threaded or coupled with a hinge pin.

To accept the hinge pin, the belt fasteners form a general U-shape orV-shape so they have has opposed side portions connected by a bend. Thebelt fasteners are connected to the belt ends with rivets having a headagainst a first side portion of the belt fastener, a shank passingthrough an opening in the first side portion of the belt fastener andthrough the belt material, and a swage end passing through an opening ina second side portion of the belt fastener and deformed around theopening.

The secured belt fasteners thus act as hinge knuckles. Each belt end hasone or more belt fasteners secured with the belt so that the bend of theU-shape provides a lateral passage. The belt fasteners of opposite beltends are positioned so that their respective lateral passages arealigned for receiving the hinge pin therein.

Optimal belt performance is related to proper connection between thebelt ends and, hence, between the belt fasteners with the belt ends. Thethickness of various belts may range, for instance, from one-eighth ofan inch to over an inch. The rivets are provided with a frangible orreleasable pilot nail shank for perceiving the belt material as therivet is driven through, for driving, a central longitudinal axis of therivet is aligned with the openings in the first and second opposed sideportions of the belt fastener and then driven through. The driving notonly drives the rivet through the belt material but also swages therivet around the second opening. This requires a significant amount offorce which, if not properly applied, may result in misalignment of therivets with the belt fastener openings. That is, if the rivet is notstarted in the proper plane or at the proper angle, and is struck bythis large force, it will miss the opening in the second side portion.

One manner known for aligning the rivets prior to and during driving isutilizing a guide block. The known guide block is formed of rubber orthe like with one or more pilot holes. The guide block pilot is placedover the belt fastener so that the pilot holes are aligned with beltfastener openings. Each pilot hole is tapered inwardly so that the rivetis generally constrained and directed towards a center point of the beltfastener openings as the rivet is being driven, the lowest portion ofthe pilot hole being smaller than the pilot nail shank, which itself issmaller than the rivet head that also must pass through the guide block.

In order to facilitate the rivet passing through the guide block,particular lubricants are required within the pilot hole. Theselubricants are selected to minimize chemical interaction between thelubricant or, rather, chemical attack by the lubricant against the guideblock. Nonetheless, as these guide blocks are often used in repairsituations deep within an underground mine where organic materials suchas coal and methane gas are prevalent, the guide blocks are susceptibleto chemical attack and damage from their environment alone.

The forces required in driving the rivets often result in damage to theguide blocks. As the lowest portion of the pilot hole is smaller thanthe pilot nail shank, forcing the shank through the hole causes at leastcyclic damage. The rubber of the guide block is at least slightlydeformable, and an improperly aligned driving tool used with a hammer,such as a single rivet driver and a 1-pound hammer, cause additionaldamage. However, of greater concern is the use of non-manual or powereddriving tools, such as a pneumatic hammer.

A pneumatic hammer uses a series of blows to drive the rivet into andthrough belt and belt fasteners. Depending on the type of pneumatichammer, a rivet may be secured with 3-5 large blows, or 3000-5000smaller blows. In any event, this requires a large amount of air andproduces impulse forces which cause significant damage to the guideblock within the pilot holes. Within a finite number of uses, the guideblock is useless because the damage to the interior of the pilot holeshas not only removed the inward taper but also resulted in an outwardtaper.

As it is undesirable and expensive to simply treat the guide blocks asdisposable, one approach for providing a guide for a pneumatic hammer isshown and described in U.S. Pat. No. 5,487,217, to Richardson, et al.The '217 patent shows use of a guide template having guide holes, theguide template being placed on the first side portion of the beltfastener and with the guide holes aligned with the openings in the beltfastener. The guide template is, when compared with a guide block,relatively thin and is formed of a generally rigid material. The drivingtool is provided with an assembly barrel that is placed within oragainst the guide holes to assume a particular orientation therewithand, thus, provides the alignment function of the guide block, asdescribed above. However, this guide template is best used with a toolhaving the assembly barrel or another alignment structure cooperatingwith the guide template to position the rivet for driving in the desiredalignment. Conversely, this guide template is not as effective withmanual tools that lack the described assembly barrel or anotheralignment structure. That is, a single driver is not effective utilizedwith the guide template as it may easily be misaligned.

There are many different typical installation scenarios for conveyorbelts of the type described herein. The belts may be installed in anindustrial or manufacturing plant. Power plants, such as coal-burningpower plants, use conveyor belt systems to move coal from train hoppersto a coal pile, from the coal pile to grinding machines, and from thegrinding machines to the ovens for burning the coal. The miningindustry, in particular, makes extensive use of these heavy-dutyconveyor belt systems, in both above-ground and below-groundinstallations.

In many installations, particular mining, belt scrapers are installed aspart of the belt systems to remove matter that may become stuck to thebelt. As the belts move at relatively high speeds, it is easy for thebelt scrapers to damage the belts. In fact, a considerable amount ofattention is being paid to designing belt scrapers that are able to giveor flex when a scraper blade gets caught on a belt.

Together, these different installation scenarios present a number ofissues, for belt systems including belt scrapers, breaking of the beltor damage thereto that is extensive enough to require repair isrelatively common and expected. During this time, the belt must be outof service, halting the up-stream loading of material and halting thedown-stream unloading of materials. For instance, a particular part of acoal mine may be unable to send its ore out of the mine, or a portion ofa commercial distribution center may come to a standstill while the beltis being repaired. This places a particular emphasis on the speed inwhich the bell is repaired.

In some instances, a belt fastener installation may be performed using asingle driver, having a single drive rod. However, field installersgenerally believe this is a relatively slow and labor-intensiveinstallation.

Multi-rivet drivers have been developed which field installers believeto be faster than the single driver. A known multi-rivet driver includesa head and a plurality of drive rods depending therefrom. The drive rodsare inserted within a guide block positioned on top of the beltfastener. Each belt fastener has a pair of openings for each rivet, andthe belt fastener has a plurality of such pairs for multiple rivets. Forinstance, the belt fastener may be secured with five rivets, and themulti-rivet driver has five drive rods used with five pilot holes of theguide block. As five rivets are simultaneously being driven, a largerhammer is used such as a four or five pound hammer. Regardless, multiplestrokes are required to drive and swage the multiple rivets.

Commonly, installation or repair with a multi-rivet driver is performedby a pair of repairpersons, one who places the multi-rivet driver in theguide block and a second who swings the hammer. This presents a safetyissue as the first repairperson may realize or believe the rivets arefully secured, prompting him or her to reach for the multi-rivet driver.The second repairperson, not having the same belief as to the securementof the rivets, may continue to swing the hammer during which time thefirst repairperson's hands may be within the path of the hammer. This isknown to cause injury to repairpersons, including the loss of fingers.

Early multi-rivet drivers were a unitary piece formed of steel, whichresulted in a short-life span due to stress concentrations between ahead or cap portion, which formed the anvil struck by the hammer, andthe drive rods. In order to promote and extend the life of these tools,other multi-rivet drivers were developed that allow the drive rods todeflect relative to each other, thereby reducing the stressconcentrations between the cap and the drive rods. In one form, theprior multi-rivet driver includes a rigid cap or anvil portion, and adeformable round insert or block for holding the drive rods, the blockbeing secured within the cap. In use, however, these drivers produceduneven or unsatisfactory compression of the belt fastener on the belt,and rivets that are not fully driven and seated, each of which therebyconcentrates stresses and belt tension forces on the rivets.

In greater detail, the opposed sides of the belt fastener are somewhatopen prior to the rivets being driven in comparison to after having therivets driven. This allows the belt end or splice end to be insertedbetween the sides of the belt fastener. The belt fastener is thencompressed on the belt end as the rivets are driven. When the knownmulti-rivet driver having deflecting rods is used, the drive rodsfarthest from the bend of the belt fastener contact and begin tocompress the belt fastener before the driver rods closest to the bend doso. As such, this portion of the belt fastener deforms somewhat, therebyreducing the ability of the belt fastener portions to be compressed intoa parallel manner, instead being slightly arched. This reduces theload-sharing capabilities of the belt fastener by causing stressconcentrations.

One option for overcoming the deficiencies of the manual tools is byusing a pneumatic hammer which, by definition, requires a source ofcompressed air. In underground mining operations, certain difficultiesare presented in using pneumatic tools. Subterranean mine air issomewhat different than surface air, containing a higher content ofeasily compressed gas, and so does not work well with pneumatic tools.Furthermore, because of the content of organic gasses such as methane inmine air, compressing this gas sometimes presents a safety concern. Atthe minimum, it is, at times, undesirable to run a fossil-fuel engine ona compressor in a mine for a variety of known reasons.

Because of the issues attendant to each of the different tools used forinstalling belt fasteners on belt splice ends, there has been a need foran improved belt fastening system and for improved tools for performingthe operation.

SUMMARY

In accordance with an aspect, a guide assembly for use with a driver forsecuring a belt fastener and a belt with a rivet is disclosed. The guideassembly may be used with a single-rivet driver, a multi-rivet driver, apneumatic driver or an electric driver.

The guide assembly includes a guide member having a plurality of pilotholes and being positionable in registry with corresponding rivet holesin the belt fastener, a support for the guide member which permittingthe rivet to be driven into the belt and belt fastener and a resilientlydeflectable guide layer secured between the guide plate and guidemember. The guide layer has a centering portion in registry with theguide member holes, the centering portion generally aligning the rivetwith the belt fastener rivet hole for securing the belt fastener andbelt.

Preferably, the guide member is a guide block formed of generally rigidmaterial. The pilot holes are preferably generally cylindrical, withouta taper. The pilot holes are generally sized to be greater than the sizeof the rivets. In this manner, the guide block avoids the issues presentwith known rubber guide blocks, that being chemical attack of the rubberand destruction of the comparatively soft material.

Preferably, the guide support is a plate having holes therein. The holesare aligned with the pilot holes of the guide member and, as such arealigned or in registry with the guide member holes and guide layercentering portion.

Preferably, the guide support, guide layer, and guide member are securedby removable fasteners. As a result, the fasteners may easily be removedto replace a damaged portion of the guide assembly.

The centering portion includes openings centered in registry with thebelt fastener rivet holes, with the pilot hole of the guide member, andwith the holes of the support plate. The guide layer centering portionmay also include a plurality of deflectable flaps defined byintersecting slits. The intersecting slits may include a pair oforthogonal equal-length slits, forming a cross-hair-like opening. Thecentering portion may further include a circular opening or cut-outcentered on the intersection between the slits.

In another aspect, belt splice assembly for facilitating securement of abelt and belt fasteners with a plurality of rivets is disclosed, eachbelt fastener having a plurality of holes in a predetermined arrangementfor receiving the plurality of rivets. The belt splice assembly mayinclude a guide block having a plurality of pilot holes arranged tocorrespond to each of the belt fastener holes, a swaging portion forsecuring rivets driven through the belt fastener and belt, guide bores,and guide pins receivable by the guide bores, the guide bores and guidepins configured to align the pilot holes of the guide block with thebelt fastener holes.

In one form, the swaging portion includes a plurality of raised portionson a plate, the raised portions aligned with respective belt fastenerholes. The raised portions each may include a bore having a centrallongitudinal axis aligned with a central longitudinal axis of therespective belt fastener holes. The pilot holes are preferablysubstantially cylindrical, and non-tapered, and the guide block ispreferably substantially rigid.

In some forms, the belt splice assembly may include a first assemblyincluding the guide block, and a second assembly including the swagingportion, the first and second assemblies cooperable to align the pilotholes with the belt fastener holes. The second assembly preferablyincludes a base, and the swage portion is located on a top surface ofthe base. The second assembly also preferably includes retentionstructure for receiving and aligning a plurality of the belt fasteners,such as with a series of throughbores and a rod insertable within thethroughbores and within the belt fasteners.

In some forms, the first assembly may include a guide layer positionedbelow the guide block, the guide layer substantially aligning a centrallongitudinal axis of each rivet with a central longitudinal axis of arespective belt fastener hole. The guide layer includes a plurality ofopenings aligned with the pilot holes, and each opening has at least afirst deflectable portion. Preferably, the guide layer openings have asubstantially closed configuration, and the deflectable portion orportions are shiftable to a substantially open configuration duringreceipt of a rivet therethrough. Preferably, each guide layer openingincludes a plurality of slits defining the deflectable portions. Theguide layer opening may further include a central cut-out allowing aportion of a rivet to be received therein with the opening in the closedconfiguration, the cut-out having a center substantially aligned withthe longitudinal axis of the belt fastener hole.

In another form, the belt splice assembly includes a first assemblyincluding the guide block and guide pins, and a second assemblyincluding the swaging portion and guide bores, the first and secondassemblies cooperable to align the pilot holes with the belt fastenerholes. The second assembly may include a base having at least a firstbase block located on a top surface thereof, and the guide bores may beformed in the base blocks.

In a further aspect, a multi-rivet driving tool for securing rivets witha belt and a belt fastener is disclosed. The driving tool includes ahead, a plurality of drive rods having at least a lower portiondepending from the head and having a predetermined arrangementcorresponding to a predetermined arrangement of rivet holes in the beltfastener, and a handle extending laterally from the head formanipulating the driving tool. In use, an operator's hands need to beplaced in the potential path of a hammer, thus reducing the likelihoodof an accident from a pair of repairpersons using the multi-rivetdriving tool.

Preferably, the driving tool head includes an outer cap having an anvilportion or surface on a top surface of the cap for being struck fordriving the rivets, and having an inner cavity for receiving an innermounting portion. The inner mounting portion may have throughbores forreceiving an upper portion of each drive rod therethrough. Each driverod may have a top portion with an enlarged head so that the drive rodhead is held in an interference position with the mounting portion.Preferably, the cap and mounting portion are generally rigid, and themounting portion is press-fit within the cap inner cavity. Thiseliminates the deflecting of prior art multi-rivet drivers, therebyresulting in improved compression of the belt fasteners and securing ofthe rivets.

In still a further aspect, a driving tool for securing a rivet with abelt and a belt fastener, the driving tool operable with an electrichammer having a chuck for receiving the driving tool therein, isdisclosed. Heretofore, electric hammers had not been used for securingrivets. The driving tool used with the electric hammer is a bit having achuck end receivable in the electric hammer chuck, an elongated shaftextending from the chuck end, and a tip having a terminal surface forcontacting and driving a rivet. The bit tip preferably includes abeveled edge. The bit tip terminal surface is preferably substantiallyflat. The bit tip terminal surface is preferably generally non-cutting.The elongated shaft is generally cylindrical so that little to no damageis caused to any guide member or block used in conjunction with theelectric hammer and bit.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a belt end, five belt fasteners, and amounting assembly for positioning the belt end and belt fasteners forsecurement on the belt end showing the belt fasteners secured with thebelt end by rivets;

FIG. 2 is a top plan view of the mounting assembly, belt end, and beltfasteners of FIG. 1 from a direction of rivet insertion or driving,showing a guide rod for positioning and aligning the belt fasteners, theguide rod received within the belt fasteners and within guide eyes ofthe mounting assembly;

FIG. 3 is a top plan view similar to FIG. 2 with the belt end and beltfasteners removed to show the mounting assembly having a swage platepositioned on top, the swage plate being below the belt fasteners andbelt during securement for swaging the rivets;

FIG. 4 is a perspective view similar to FIG. 1 showing the mountingassembly with a guide assembly positioned atop the belt end and beltfasteners for aligning rivets in a proper orientation during driving,the guide assembly having pilot holes in a predetermined arrangement forsecuring the belt fasteners with the belt end;

FIG. 5 is a top plan view of the mounting assembly and guide assembly ofFIG. 4 showing guide pins of the guide assembly in phantom and receivedin base blocks of the mounting assembly for aligning the guide assemblyin proper orientation with the mounting assembly and belt fastenersduring driving of the rivets;

FIG. 6 is a perspective view of the guide assembly of FIG. 4 showing aguide plate supporting a guide block having a pre-determined arrangementof pilot holes for receiving rivets for securing the belt fastener withthe belt end;

FIG. 7 is a side elevation view of the guide assembly of FIG. 6 showingthe guide pins extending from the guide plate, a centering guidemembrane interposed between the guide block and the guide plate, and thepilot holes in phantom;

FIG. 8 is an exploded view of the guide assembly of FIGS. 4-7 showingmounting screws for securing the guide plate with the guide block withthe guide membrane therebetween;

FIG. 9 is a top plan view of the guide membrane showing slit patternsaligned with and positioned between portions of the pilot holes in theguide block and guide plate;

FIG. 10 is a perspective view of a second form of a guide assemblyhaving pilot holes in a pre-determined pattern for securing eight beltfasteners with a belt end;

FIG. 11 is a cross-sectional view of a single driver for driving asingle rivet through a belt fastener and belt for securementtherebetween, a first rivet being positioned in the pilot hole of theguide block and a second rivet having been swaged by the swage plate ofthe mounting assembly;

FIG. 12 is a cross-sectional view of a belt fastener being secured witha belt, a swage plate positioned below the belt fastener and a guideassembly positioned thereabove, a rivet being shown in three differentpositions during the driving process;

FIG. 13 is perspective view of a hammer and the single driver of FIG. 11for securing a single rivet;

FIG. 14 is a perspective view of a second hammer and a multi-driver forsimultaneously driving a plurality of rivets in a predeterminedarrangement;

FIG. 15 is a cross-sectional view of the multi-driver of FIG. 14 showinga plurality of drive rods secured within an anvil cap;

FIG. 16 is a perspective view of a pneumatic driving tool having a drivebit for securing a rivet;

FIG. 17 is a side elevation view of the drive bit of FIG. 16 showing acollet end for securing with the pneumatic driving tool;

FIG. 18 is a perspective view of an electric driving tool having a drivebit for securing a rivet; and

FIG. 19 is a side elevation view of the drive bit of FIG. 18 showing aslotted chuck end for securing with the electric driving tool.

DETAILED DESCRIPTION

Referring initially to FIG. 1, a mounting assembly 10 of the presentinvention is shown with a belt end 12 of a conveyor belt 14 positionedwithin and secured with a plurality of belt fasteners 16. In use, themounting assembly 10 generally retains and positions each of the beltfasteners 16 in a predetermined alignment relative thereto. The belt end12 is then inserted within the belt fasteners 16, at which point rivets18 are driven through the belt end 12 and the belt fasteners 16 forsecuring the belt end 12, belt fasteners 16, and rivets 18. The belt end12 and the belt fasteners 16 are then secured, hinge-like, with a secondbelt end 12 to form a belt splice or connection.

With reference to FIG. 4, a guide assembly 30 is utilized with themounting assembly 10 for proper alignment of the rivets 18 during theirdriving into and through the belt end 12 and belt fasteners 16. Theguide assembly 30 includes a guide block 32 secured with and supportedby a guide plate 36, through both of which pilot holes 34 are formed fordirecting the rivet 18 generally in a desired and proper orientation forsecuring the belt end 12 and belt fastener 16. Between the guide block32 and guide plate 36 is a guide interposer or membrane 38 for centeringeach rivet 18 during driving. The pilot holes 34 are sized to receive avariety of driving tools therethrough for driving the rivets 18. Each ofthese will be discussed in further detail below.

Referring generally to FIGS. 1-2 and specifically to FIG. 3, themounting assembly 10 is used to support a belt 12 during a splicing orrepair operation, which is essentially a belt fastener installation.That is, in order to repair a belt or splice two ends 12 of the belt 14when the belt 14 fails or is damaged in service, the mounting assembly10 is transported to the belt 14 at the repair site for providing asplice between the two belt ends 12. It should be noted that the belt 14need not actually sever in order for a splice to be performed. Forinstance, the belt 14 may simply be damaged in a manner that makesoperating the belt 14 in its current condition inefficient, dangerous,or likely to fail in a short period of time. In some instances,repairpersons may manually and intentionally sever the belt in order toprovide belt ends 12 that are suitable for splicing, suitabilityincluding a leading edge 12 a which is generally orthogonal to thedirection of belt travel such that belt fasteners 16 may be oriented andsecured orthogonal to the direction of belt travel. Beneficially, thecloser the belt fasteners 16 are this to orientation, the more the beltfasteners 16 are able to distribute forces across their extent.

To facilitate transport to a repair site, the mounting assembly 10 ispreferably generally lightweight and compact. As an example, themounting assembly 10 may have a width W1 which is not extensivelygreater than a width W2 of the belt 14. As shown in FIG. 2, the width W2of the belt 14 is smaller than the width W3 of a swage plate 70,discussed below. Accordingly, the presently depicted mounting assembly10 may be used for repair belts having a larger width than the width W2of the presently shown belt 14.

In specific, the mounting assembly 10 includes a base 40 having theprovided width W1. The base 40 has a top wall 42 having a generally flattop surface 42 a. Extending downward from the top wall 42 are laterallyextending support walls 44 such that the base 40 generally forms achannel 46. The support walls 44 are generally tapered and theapplication of force to the top of the mounting assembly 10 allows alower edge 44 a of each support wall 44 to dig into an earthen supportsurface, such as the floor of a mine, which assists in stabilizing themounting assembly during use, particularly when the support surface isnot completely level. In a preferred form, the base 40 is generally alightweight and strong material that is relatively chemically resistantfor use in environments such as mines where active chemicals arepresent, such a material being aluminum. It is also preferred to providethe mounting assembly 10 with a carrying handle 48. As depicted, thehandle 48 is generally a square U-shape with first and second threadedends 50 secured in holes (not shown) of one of the support walls 44 vianuts 52. In this manner, the carrying handle 48 can be easily mounted orremoved.

As noted above, the mounting assembly 10 includes a swage plate 70 forswaging the rivet 18, the cooperation between which will be discussedbelow. The swage plate 70 is secured with the base 40, via securementssuch as bolts 71, and is designed for use with a particular type of beltfastener 16. Accordingly, if different types of belt fasteners 16 are tobe used, the swage plate 70 may be removed to allow for a differentswage plate (not shown) corresponding to another belt fastener type tobe used. For instance, the presently depicted belt fasteners 16 eachhave a predetermined arrangement for five rivets 18, and the swage plate70 has a set 74 of swage structures 72 corresponding to each of the fiverivets 18, and the swage plate 70 has sets 74 of swage structures 72 foreach of the belt fasteners 16. As can be seen in FIG. 3, the swage plate70 includes eight sets 74 of swage structures 72 which may be used forup to eight belt fasteners 16.

The swage plate 70 has top and bottom surfaces 76, 78 which are eachgenerally flat. Secured to the swage plate top surface 76 is a series ofguide eyes 80. Each guide eye 80 has a throughbore 82 extendinggenerally in a lateral direction of the belt end 12, and thethroughbores 82 are aligned with each other.

To position the belt fasteners 16 with the mounting assembly 10, thebelt fasteners 16 are aligned with the throughbores 82 of the guide eyes80. In greater detail, each belt fastener 16 is generally U-shaped orV-shaped so that each has two side portions 86 and a curved portion orbend portion 88 connecting the side portions 86 to form a channel ortrough 88 therethrough. The belt fastener 16 is placed on top of theswage plate top surface 76 with a first side portion 86 a facing upwardand a second side portion 86 b facing downward and against the topsurface 76. The trough 88 is aligned with the guide eye throughbores 82.To retain the belt fasteners 16 with the mounting assembly, a guide rod90 is inserted through each of the aligned guide eye throughbores 82 andthrough each of the troughs 88 of the belt fasteners 16. Thus, the beltfasteners 16 are generally prevented from separating from the mountingassembly 10 by the guide rod 90, by internal stops (not shown) betweenthe side portions and in an interference position with the guide rod 90,and by base blocks 92, which will be discussed in greater detail below.

For ease of transport, the guide rod 90 is retained with the base 40. Asshown, the base 40 includes a pair of retainers 94. Each retainer 94 isgenerally U-shaped having a first leg 96 and a second leg 98 and a bend100. Each leg 96, 98 of the retainer 94 passes through a hole 102 in thetop wall 42, and the bend 100 is positioned above the top wall 42. Thefirst leg 96 has a spring 104 positioned therearound, the spring 104retained by a head 106. When upward force is applied to the retainer 94,the spring 104 is compressed and the bend 100 moves away from the topwall 42, thereby allowing the guide rod 90 to be received between thebend and the top wall 42. Once the upward force is released, the spring104 draws the retainer 94 downward so that the guide rod 90 is clampedbetween the bend 100 and the top wall 42.

Once the belt fasteners 16 are retained with the mounting assembly 10 bythe guide rod 90, the belt end 12 may be inserted between the sideportions 86 of the belt fastener 16. That is, the belt leading end 12 ais inserted between the belt fastener side portions 86 and the belt 14is positioned so that the direction of travel for the belt 14 isgenerally orthogonal to the direction of the guide rod 90. Each beltfastener 16 has the internal stop (not shown) between the side portions86 that limits the depth of insertion for the belt leading end 12 a.

In this arrangement, the belt fasteners 16 are generally aligned withthe swage structures 72. For the presently depicted embodiment, the beltfasteners 16 are designed for receiving five rivets 18 each. Each sideportion 86 of the belt fastener 16 has a five rivet holes 110, and eachis aligned with a respective rivet hole 110 of the opposed side portion86. The rivet holes 110 are in a predetermined arrangement, and theswage structures 72 are arrayed in a matching arrangement. Accordingly,the rivet holes 110 of the side portions 86 and the swage structures 72are aligned so that the rivets 18 may be driven through the beltfastener 16 and belt 14 and then swaged around the lower side portion 86b, either sequentially or simultaneously.

Referring generally to FIGS. 4 and 5 and, more specifically, to FIGS.6-9, the mounting assembly 10 cooperates with the previously-mentionedguide assembly 30 to align the rivets 18 with the rivet holes 110. Asnoted, the guide assembly 30 includes pilot holes 34 formed in the guideblock 32 and guide plate 36. The pilot holes 34 are generallycylindrical, as opposed to the tapered pilot holes of prior guideblocks, so that the rivets 18 easily pass therethrough with minimalcontact and damage to the guide assembly 30. In prior blocks, taperedpilot holes were used to center the rivets with the rivet holes of thebelt fastener during driving. The present guide assembly 30 includes arelatively tall guide block 32 which, despite tolerances between thepilot holes 34 therein and the rivets 18, minimizes the deviation of therivet 18 during driving. Preferably, the guide block 32 is formed ofultra-high molecular weight polyethylene. This material is rigid andtough and resistant to wear, is self-lubricating, is stable in a miningenvironment, and has a low sliding coefficient of friction, particularlywhen used with the metal drivers, as is discussed herein. Ideally, thealignment of the rivet 18 during driving is such that its longitudinalcentral axis is aligned with an axis through the rivet holes 110provided for the rivet in the opposed side portions 86 of the beltfastener 16.

In order to center and align the axis of the rivet 18 with the axis ofits respective rivet holes 110, the guide membrane 38 is providedbetween the guide block 32 and the guide plate 36. As can be seen, theguide membrane 38 is relative thin, in the order of one-eighth of aninch to one sixteenth of an inch, while the guide block 32 has a heightin the order of two and a quarter inches. The guide block 32 and guideplate 36 are secured together, with the guide membrane 38 between, viaremovable fasteners such as screws 120 (FIG. 8). Preferably, the screws120 have a socket head 120 a, a threaded shank portion 120 b, and anon-threaded shank portion 120 c. The non-threaded portion 102 c isclosely fit within its respective hole 121 in the guide block 32 so thatthe screw 120 serves to help locate the guide block 32 relative to theguide plate 36, as well as to assist in maintaining that location. Inthis manner, the guide membrane 38 is somewhat compressed between theguide block 32 and guide plate 36.

The guide membrane 38 is formed of a relatively soft rubber material.Preferably, the guide membrane 38 is formed of a chemically-resistantrubber having a 900 psi tensile strength and elongation limit of 300%.An example of a preferred material is sold as “Ultra-Strength NeopreneRubber” by McMaster-Carr of Elmhurst, Ill. This material providesstrength, organic chemical resistance, and flame resistance, with atensile strength of 2500 psi and stretch elongation limit of 450%.

As can be seen best in FIGS. 8 and 9, the guide membrane 38 has a seriesof holes therethrough. As shown, three holes 122 are provided for thescrews 120 to pass through for securing components of the guide assembly30. The other holes are centering holes 124 provided with a slit pattern126 for centering the rivets 18 during driving.

In specific, the slit pattern 126 includes a pair of orthogonal,cross-hair equal-length slits 128 extending through the guide membrane38. Centered on the cross-hair slits 128 is a small circular cut-out 130where the material has been removed. The cross-hair slits 128 definefour flaps 129. Alternatively, slits may be provided for defining threeflaps, or greater than four flaps.

As is known, a standard belt fastener rivet 18 has a head 132, a shank134 at least a leading portion of which is hollow or annular, an annularleading end 136 for the shank 134, and a pilot nail 138 (see FIGS. 11and 12). The rivet 18 passes through the pilot hole 34 portion of theguide block 32 and the pilot nail 138 is centered by the cut-out 130. Asthe rivet 18 continues downward, the rivet 18 forces the flaps 129downward (into the pilot hole 34 portion formed in the guide plate 36)to allow the rivet 18 to pass through. The forces on the rivet 18applied by the resiliently deflected flaps 129 is balanced to retain therivet 18 in a generally centered position. The rivet 18 then passesthrough the pilot hole 34 portion of the guide plate 36, at which pointthe rivet 18 is then driven through the belt fastener rivet holes 110and the belt 14. As is also known, the pilot nail 138 is frangible orreleasable. In this manner, the leading end 136 of the shank 134 isdeformed or swaged around the lower belt fastener side portion 86, andthe pilot nail 138 is separated the rivet 18 during or after theswaging. As noted, the guide membrane 34 is compressed between the guideblock 32 and guide plate 36 so that stretching and/or deformation of theguide membrane 34 is localized at the flaps 129. Once the rivet 18 isdriven, the driving tool (discussed below) is removed and the flaps 129return to their natural position. In this configuration, thelife-expectancy of the guide assembly 30 is significantly increased incomparison to the prior guide blocks, and there is no need forlubricants.

Prior to driving of the rivets 18, the guide assembly 30 is aligned withthe mounting assembly 10. For this, the guide plate 36 of the guideassembly 30 includes guide pins 140 extending orthogonally from a bottomside of the guide plate 36, as best seen in FIG. 7. Preferably, theguide plate 36 includes throughbores 142 extending through the guideplate 36, and the guide pins 140 are secured within the throughbores142. Each guide pin 140 may be secured via press-fitting, and may havean enlarged head portion 141 assisting in maintaining the properalignment of the guide pin 140 relative to the guide plate 36.Preferably, the guide pins 140 are welded within the guide plate 36after they are press-fit therein. This construction minimizes stressconcentrations that may arise from securing the guide pins 140 to thebottom side of the guide block 36, as well as minimizes the likelihoodof accidental bumps or strikes to bend the guide pins 140.

To position the guide assembly 30 with the mounting assembly 10, theguide pins 140 are registered with and received within the guide blocks92, noted above. In the present embodiment, the guide pins 140 arecircular or cylindrical such that at least a pair is used for properregistry. However, a single guide pin may be used with an irregular ornon-circular shape so that proper registry is defined by the receipt ofthe non-circular guide pin with a corresponding port formed in themounting assembly 10. Further, the present embodiment utilizes the guideblocks 92 having a height H. The height H is partly provided in respectfor the expected thickness of the belt 14 and belt fasteners 16. Moreimportantly, the height H provides a depth of receipt by guide bores 150formed in the guide blocks 92 for receiving the guide pins 140. While atolerance is provided between the outer diameter of the guide pins 140and the inner diameter of the guide bores 150, the ability of the guidepins 140, and hence the guide assembly 30 itself, to deviate from properalignment is minimized by the dept of the insertion of the guide pins140 within the guide bores 150. Accordingly, the guide blocks 92 aresized to maximize the receipt of the guide pins 140 therewithin, whilealso being sized to allow the guide assembly 30 to be positionedproximate the top belt fastener side portion 86 a as the rivets 18 aredriven and the belt fastener side portions 86 are compressed. Thisminimizes the ability of the rivets 18 to deviate from the desireddirection of driving after the pilot nail 74 passes through the guideplate 36. In one form, a bottom side of the guide plate 36 may rest on atop surface of guide blocks 92 during use.

The guide assembly 30, as discussed, provides pilot holes 34 for aparticular number of belt fasteners 16. For instance, FIG. 5 shows theguide block 32 having four sets 160 of pilot holes 34. The swage plate70, however, has eight sets 74 of swage structures 72, one set for eachbelt fastener 16. It is noted that, as shown, the swage plate 70includes first and second swage plate portions 70 a and 70 b. The numberof pilot hole sets 160 and swage structure sets 74 may be varied asdesired or for particular applications, as well as the configuration ofeach set 160, 74 for various belt fastener configurations. However, eachof these may use standard pilot-nail rivets provided by a number ofknown manufacturers. In an alternative embodiment, shown in FIG. 10, aguide assembly 170 is provided having eight sets 172 of pilot holes 174.For wide bells, the four-set guide assembly 30 may be used in a firstposition for securing a first group of belt fasteners 16, and it may berepositioned for securing a second group of belt fasteners 16.Alternatively, the eight-set guide assembly 170 may be used for securingup to eight belt fasteners 16 without repositioning. In common industryusage, it is known that belts 14 may be 96 inches wide, or greater.Accordingly, the guide assemblies 30 and 170 and the mounting assemblymay be adapted for a range of belt widths, as desired.

As various guide assemblies, such as the guide assemblies 30 and 170, orothers, may be used with the mounting assembly 10, the mounting assembly10 provides a plurality of the guide blocks 92 such that guide pins 140on each of the guide assemblies 30, 170 may be registered and receivedtherewith. As shown in the present embodiment, the mounting assembly 30includes four guide blocks 92, the guide bores 150 formed therein beingpositioned for proper registry of the guide pins 140 and guideassemblies 30 with the rivet holes 110 of the belt fasteners 16.

As discussed, the rivet 18 has the rivet head 132, the shank 134, andthe pilot nail 138. The shank 134 is at least partially, and possiblyfully, annular so that a cylindrical cavity 210 is formed therewithin.The pilot nail 138 has a nail shank 212 with a conical or otherwisepointed lower tip 214 and an outwardly flaring or conical portion 216above the tip 214, the conical portion 216 forming an upper shoulder 218with the nail shank 212. The nail shank 212 is received within thecavity 210 with the upper shoulder 218 abutting the rivet shank 134.More specifically, the rivet shank leading end 136 forms a rivetshoulder 220 positioned against or close to the shank upper shoulder218.

The operation of the swage plate 70 in cooperation with the rivet 18 isdescribed in U.S. Pat. No. 5,680,790, to Richardson, et al., theentirety of which is fully incorporated herein by reference. In simpleterms, the each swage plate swage structure 72 is formed by a hole 230in the swage plate 70 and surrounded by a raised, annular swagingshoulder 232. As the rivet 18 is driven through the belt 14 and beltfastener 16, the pilot nail 138 extends through the belt fastener lowerside portion 86 b and enters the hole 230. With continued driving, thenail shank conical portion 216 contacts the swaging shoulder 232 andcompresses, whereupon the rivet shank leading end 136 contacts theswaging shoulder 232. The rivet shank 134 flares outward as it is drivenagainst the swaging shoulder 232, thus wrapping around to secure therivet 18 against the bottom belt fastener side portion 86 b.

For performing a splice operation for joining two ends 12 of the belt14, one or more repairmen transport the lightweight mounting assembly 10and guide assembly 30 to a work site, such as in a mine. The guide pins140 of the guide assembly 30 may be received by the guide bores 150 ofthe mounting assembly guide blocks 92 so that the mounting assembly 10and guide assembly 30 may be transported as a single unit. The mountingassembly 10 is positioned on the support surface in a desired locationfor performing the operation. The guide rod 90 is removed from theretainers 94. A plurality of selected belt fasteners 16 are positionedon the swage plate 70, and the guide rod 90 is inserted through the bellfasteners 16 and through the guide eye throughbores 82. The belt end 12is then inserted into the belt fastener side portions 86. The guideassembly 30 is then positioned above the mounting assembly 10 so thatthe guide pins 140 can be inserted into the guide bores 150. The guideassembly 30 is then lowered. Thus, proper alignment is provided for thepilot holes 34 of the guide block 32 and guide plate 36, the cut-out130, the belt fastener rivet holes 110, and the swage structures 72. Fordriving each rivet 18, the rivet 18 is placed in the pilot hole 34 ofthe guide block 32 with the pilot nail tip 214 self-centering in thecut-out 130 of the guide membrane 38. Next, the user selects a driverfor securing the rivets 18 in the manner described above.

The guide assembly 30 and mounting assembly 10 may be used with avariety of driving tools. More specifically, the pilot holes 34 aresized and arranged for use with driving tools depicted in FIGS. 11-19.With initial reference to FIGS. 11-13, a representative driver is shownfor driving a standard belt fastener rivet 18. As shown, the driver is asingle-rivet driver 200 having a handle 202 for gripping and handlingthe driver 200 and a central shaft 204 secured with the handle 202. Alower portion of the central shaft 204 is a cylindrical drive rod 206having a chamfered peripheral edge 208. The single-rivet driver 200 isgenerally used with a framing weight hammer, such as a 16-ounce hammer240, shown in FIG. 13. With the rivet 18 positioned within the pilothole 34, the drive rod 200 is inserted into the pilot hole 34 and pushesdown on the rivet 18 so that the rivet nail tip 214 deflects themembrane flaps 129 downward and outward. The flaps 129 maintain contactwith the rivet 18 so the rivet 18 remains centered. The hammer 240 isthen used to strike the driver 200 to drive and secure the rivet 18.

As discussed, the guide block 32 includes a plurality of pilot holes 34arranged to be in registry with the rivet holes 110 of the beltfasteners 16. Accordingly, a multi-rivet driver 250 may be used with theguide block 32 and guide assembly 30. With reference to FIGS. 14 and 15,the multi-rivet driver 250 is shown having five drive rods 252receivable by the guide block pilot holes 34. Each drive rod 252 is slipfit within bores 254 of a solid and incompressible, preferably metal,insert 256. The insert 256 is then press-fit within an anvil cap 258. Inthis manner, the drive rods 252 are generally restrained from deflectingduring the driving of the rivet 18. The anvil cap 258 has a top surface260 or being struck to drive the rivets 18. As discussed above, the useof prior multi-rivet drivers has occasionally presented a safety issue.Accordingly, a safety handle 262 extends from a side of the anvil cap258 for insertion into and removal from the guide block 32.

The guide block 32 may also be used with a pneumatic driver 270, shownin FIG. 16, having a drive bit 272, also shown in FIG. 17. As shown, thedrive bit 272 has a collet or chuck end 274 for use with keyless,spring-type driver chucks, known in the art, and a drive rod 276 forcontacting and driving the rivet 18. Prior use of pneumatic driversresulted in rapid deterioration and damage to prior deformable and/orsoft polymeric (rubber) guide blocks. As the present guide block 32 isgenerally rigid having pilot holes 34 slightly larger than the rivets18, the rapid driving of the rivet 18 does not damage the guide block34. The guide membrane 38 easily allows the rapid driving of the rivet18 without significant damage. Furthermore, the guide assembly 30 can berepaired or refurbished should the life of the guide membrane 38 beexpended by simply removing the screws 120. In contrast, the prior guideblocks are useless once damaged.

Referring to FIGS. 18-19, an electric driver 280 with a drive bit 282may be used with the guide assembly 30. Prior non-manual driversgenerally consisted of various pneumatic drivers. As discussed above,pneumatic drivers present a number of problems as they require a sourceof compressed gas (air), which is not always possible or safe in someenvironments, and requires transport of the compressor and tank forholding the compressed gas. In contrast, the electric driver 280requires only a source of electricity, which is relatively accessible inmost environments. Alternatively, the electric driver 280 may have abattery (deep-cell battery) and transformer for providing the requisitepower.

It should be noted that electric drivers or hammers are known. Thesetools typically are high-powered, having a wattage rating in excess of1000 W. Therefore, electric drivers are typically rated as demolitiononly. That is, they are not used for driving nails, like a hand hammerwould be used, instead being used either to break a structure apart, todrill into a structure, or to tamp down a material.

With this common and believed to be exclusive use, electric hammers havenot previously been used for securing rivets. Instead, bits used withthe electric hammers have been used for the above-identified purposes.More specifically, electric hammer bits have generally consisted of achuck end for being secured with the electric hammer, an elongated shaftextending from the chuck end, and a bit tip at the end of the shaft.Common bits are cutter bits, chisel or spade bits, fluted tips fordrilling, or piercing bits including bull tips or circular, taperedbits. Accordingly, adaptation of an electric hammer for the presentnovel use, specifically securing rivets with a belt and belt fastener,requires a heretofore non-existent drive bit 282.

The drive bit 282 has an elongated drive rod 284 for contacting anddriving the rivet 18 at a tip 285, a peripheral edge 286 of which isbeveled and a terminal surface 287 of which is generally non-cutting,such as generally flat, slightly convex, or slightly concave. The driverod 284 has a diameter sized in a manner similar to the drive rods ofthe other drivers discussed herein and sized to be received within theguide block pilot holes. The drive rod 284 is generally cylindrical witha generally smooth exterior to minimize contact damage against a guidesuch as the guide blocks discussed herein. The drive rod tip 285 has thebeveled edge 286 to promoted driving force being directed through thecenter of the rivet 18 during driving. The drive bit 282 also has a slot295 in a chuck end 288 for securing with a driver chuck 290 of theelectric driver 280. It should be noted that the chuck end 288 may haveother structure for cooperating with driver chucks of various electricdrivers or hammers provided by different manufacturers.

While the invention has been described with respect to specific examplesincluding presently preferred modes of carrying out the invention, thoseskilled in the art will appreciate that there are numerous variationsand permutations of the above described systems and techniques that fallwithin the spirit and scope of the invention as set forth in theappended claims.

1. A belt splice assembly for facilitating securement of a belt and beltfasteners with a plurality of rivets, each belt fastener having aplurality of holes in a predetermined arrangement for receiving theplurality of rivets, the belt splice assembly comprising: a guide blockhaving a plurality of pilot holes arranged to correspond to each of thebelt fastener holes; a swaging portion for securing rivets driventhrough the belt fastener and belt; guide bores; and guide pinsreceivable by the guide bores, the guide bores and guide pins configuredto align the pilot holes of the guide block with the belt fastenerholes.
 2. The belt splice assembly of claim 1 wherein the swagingportion includes a plurality of raised portions on a plate, the raisedportions aligned with respective belt fastener holes.
 3. The belt spliceassembly of claim 2 wherein the raised portions each include a borehaving a central longitudinal axis aligned with a central longitudinalaxis of the respective belt fastener holes.
 4. The belt splice assemblyof claim 1 wherein the pilot holes are substantially cylindrical.
 5. Thebelt splice assembly of claim 1 wherein the guide block is substantiallyrigid.
 6. The belt splice assembly of claim 1 including a first assemblyincluding the guide block, and a second assembly including the swagingportion, the first and second assemblies cooperable to align the pilotholes with the belt fastener holes, the second assembly furtherincluding a base, the swage portion located on a top surface of thebase.
 7. The belt splice assembly of claim 6 wherein the second assemblyfurther includes retention structure for receiving and aligning aplurality of the belt fasteners.
 8. The belt splice assembly of claim 7wherein the retention structure includes a series of throughbores, and arod insertable within the throughbores and within the belt fasteners. 9.The belt splice assembly of claim 6 wherein the first assembly furtherincludes a guide layer positioned below the guide block, the guide layersubstantially aligning a central longitudinal axis of each rivet with acentral longitudinal axis of a respective belt fastener hole.
 10. Thebelt splice assembly of claim 9 wherein the guide layer includes aplurality of openings aligned with the pilot holes, each opening havingat least a first deflectable portion, the opening having a substantiallyclosed configuration and the deflectable portion shiftable to asubstantially open configuration during receipt of a rivet therethrough.11. The belt splice assembly of claim 10 wherein each opening includes aplurality of slits defining the deflectable portions.
 12. The beltsplice assembly of claim 10 wherein the opening further includes acentral cut-out allowing a portion of a rivet to be received thereinwith the opening in the closed configuration, the cut-out having acenter substantially aligned with the longitudinal axis of the beltfastener hole.
 13. The belt splice assembly of claim 1 including a firstassembly including the guide block and guide pins, and a second assemblyincluding the swaging portion and guide bores, the first and secondassemblies cooperating to align the pilot holes with the belt fastenerholes.
 14. The belt splice assembly of claim 13 wherein the secondassembly further includes a base having at least a first base blocklocated on a top surface thereof, the guide bores being formed in thebase blocks.